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US20220184897A1 - Resin formed article and method for producing resin formed article - Google Patents

Resin formed article and method for producing resin formed article Download PDF

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Publication number
US20220184897A1
US20220184897A1 US17/440,034 US202017440034A US2022184897A1 US 20220184897 A1 US20220184897 A1 US 20220184897A1 US 202017440034 A US202017440034 A US 202017440034A US 2022184897 A1 US2022184897 A1 US 2022184897A1
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US
United States
Prior art keywords
resin
formed article
functional layer
projection
resin formed
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
US17/440,034
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English (en)
Inventor
Noriyuki Yoshida
Yu MASUZAWA
Yoshihiro Tsuda
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Resonac Corp
Original Assignee
Showa Denko Materials Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Showa Denko Materials Co Ltd filed Critical Showa Denko Materials Co Ltd
Assigned to SHOWA DENKO MATERIALS CO., LTD. reassignment SHOWA DENKO MATERIALS CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: TSUDA, YOSHIHIRO, YOSHIDA, NORIYUKI, MASUZAWA, Yu
Publication of US20220184897A1 publication Critical patent/US20220184897A1/en
Assigned to RESONAC CORPORATION reassignment RESONAC CORPORATION CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: SHOWA DENKO MATERIALS CO., LTD.
Assigned to RESONAC CORPORATION reassignment RESONAC CORPORATION CHANGE OF ADDRESS Assignors: RESONAC CORPORATION
Pending legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14467—Joining articles or parts of a single article
    • B29C45/14508—Joining juxtaposed sheet-like articles, e.g. for making trim panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/42—Moulds or cores; Details thereof or accessories therefor characterised by the shape of the moulding surface, e.g. ribs or grooves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14311—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/46—Means for plasticising or homogenising the moulding material or forcing it into the mould
    • B29C45/56—Means for plasticising or homogenising the moulding material or forcing it into the mould using mould parts movable during or after injection, e.g. injection-compression moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B29C2045/14286—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure means for heating the insert
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14311—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
    • B29C2045/14327—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles anchoring by forcing the material to pass through a hole in the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14467—Joining articles or parts of a single article
    • B29C2045/14532—Joining articles or parts of a single article injecting between two sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products

Definitions

  • the invention relates to a resin formed article and a method for producing a resin formed article.
  • Batteries driven by electricity such as electric automobiles and hybrid automobiles, have batteries that are installed at a bottom of a car body.
  • the batteries are electrically connected with a cable, and are contained in a battery case and installed in a car body.
  • As a battery case in addition to cases made of metal, cases made of resin has been studied in order to meet demands for weight reduction, improved fuel efficiency, corrosion resistance and the like, while also shielding the car body from electromagnetic waves generated by the batteries (see, for example, Patent Document 1).
  • a battery case made of resin has a projection that is disposed at a main body for the purpose of reinforcement. Further, the battery case has an electromagnetic wave-shielding sheet that is disposed at a surface of the main body for the purpose of shielding the battery case from electromagnetic waves generated by the batteries.
  • Patent Document 1 describes a battery case having a configuration in which an electromagnetic wave-shielding sheet is disposed along a plate-like portion of a main body, and an edge of the electromagnetic wave-shielding sheet follows a side surface of a projection.
  • Patent Document 1 Japanese Patent Application Laid-Open No. 2014-213602
  • Patent Document 1 has a limited degree of freedom of shaping, since it is necessary to embed a retainer inside the projection, or to shape or trim the electromagnetic wave-shielding sheet to conform to the shape of the projection, in order to precisely dispose the electromagnetic wave-shielding sheet along the projection.
  • the present invention aims to provide a resin formed article having an excellent degree of freedom of shaping, and a method of producing a resin formed article having an excellent degree of freedom of shaping.
  • the means for solving the problem includes the following embodiments.
  • a resin formed article having an excellent degree of freedom of shaping and a method of producing a resin formed article having an excellent degree of freedom of shaping are provided.
  • FIG. 1 is a sectional view schematically showing an example of a production process of the resin formed article.
  • FIG. 2 is a sectional view schematically showing an example of a production process of the resin formed article.
  • step includes not only an independent step which is distinguishable from another step, but also a step which is not clearly distinguishable from another step, as long as the purpose of the step is achieved.
  • any numerical range described using the expression “to” represents a range in which numerical values described before and after the “to” are included in the range as a minimum value and a maximum value, respectively.
  • an upper limit value or a lower limit value described in one numerical range may be replaced with an upper limit value or a lower limit value in another numerical range described in stages.
  • the upper limit value or the lower limit value in the numerical range may be replaced with a value shown in the Examples.
  • the resin formed article according to the present disclosure is a resin formed article, comprising: a main body that includes a first resin; a functional layer that is disposed at at least a portion of a surface of the main body and includes a fiber and a second resin; and a projection that is disposed on the functional layer and includes the first resin and the second resin.
  • the resin formed article according to the present disclosure has an excellent degree of freedom of shaping. The reasons for this are explained by referring to the drawings.
  • the resin formed article according to the present disclosure is not limited to the configurations described in the drawings.
  • FIG. 1 and FIG. 2 are sectional views schematically showing an example of a production process of the resin formed article.
  • a mold 10 has a space that corresponds to a main body of the resin formed article and a first resin 1 in a melted state is supplied thereto; and a concave portion having a shape corresponding to a projection of the resin formed article.
  • a functional layer 2 including a fiber and a second resin is disposed inside the mold 10 .
  • a basal region 3 which corresponds to a basal portion of the projection, of the functional layer 2 is not in contact with the mold 10 . Accordingly, the second resin included in the basal region 3 of the functional layer is difficult to be cooled by the mold 10 , and is melted by contact with the first resin 1 . As a result, the first resin 1 is capable of permeating through the fiber included in the basal region 3 of the functional layer 2 .
  • the mold 10 is operated such that the space to which the first resin 1 has been supplied is compressed. Accordingly, a portion of the first resin 1 that has been pressurized flows toward a concave portion of the mold 10 through the fiber in the basal region 3 . Further, the second resin included in the basal region 3 of the functional layer 2 flows toward a concave portion of the mold 10 . As a result, the concave portion is filled with the first resin and the second resin, thereby forming a projection 4 . Through the process, the resin formed article according to the present disclosure is produced.
  • a projection is formed by a portion of the first resin, which forms a main body, flowing through the fiber included in the functional layer. Therefore, it is not necessary to perform a process such as hole making at a portion of the functional layer corresponding to the projection, and the resin formed article according to the present disclosure exhibits an excellent degree of freedom of shaping. Further, in the resin formed article according to the present disclosure, the main body and the projection are integrally formed via the functional layer. Therefore, the projection of the resin formed article according to the present disclosure exhibits an excellent strength, as compared with a projection that is prepared in a separate process and attached to the main body.
  • the main body of the resin formed article includes a first resin.
  • the type of the first resin is not particularly limited, and examples thereof include a thermoplastic resin.
  • the thermoplastic resin includes polyolefin such as polyethylene or polypropylene, polyester such as polycarbonate, polyamide, polyvinyl chloride, polyurethane, and acrylic resin.
  • the first resin may be selected depending on the purpose of the resin formed article.
  • the first resin may be a single kind of resin, or may be a combination of two or more kinds.
  • the melting temperature of the first resin is not particularly limited, and may be selected depending on the production method of the resin formed article and the like.
  • the melting temperature may be selected from a range of 100° C. to 300° C.
  • the main body may include a component other than the first resin.
  • the component other than the first resin include an inorganic filler, a releasing agent, a fire retardant and a colorant.
  • the main body preferably includes an inorganic filler.
  • the inorganic filler includes silica, alumina, talc, clay, mica, boron nitride and aluminum nitride.
  • the shape of the inorganic filler is not particularly limited, and the inorganic filler may be in the form of fibers, particles, beads or the like.
  • the amount thereof is not particularly limited. From the viewpoint of an effect achieved by the inorganic filler and the flowability inside the mold, the amount of the inorganic filler may be from 1 part by mass to 5 parts by mass with respect to 100 parts by mass of the first resin.
  • the shape of the main body is not particularly limited, and may be selected depending on the purpose of the resin formed article.
  • the main body may have a plate-like shape or any other desired three-dimensional shape.
  • the thickness of the main body, at a portion at which the thickness is minimum, may be 1 mm or more, or may be 3 mm or more, or may be 5 mm or more.
  • the functional layer includes a fiber and a second resin.
  • the type of the second resin is not particularly limited.
  • the second resin may be selected from the exemplary resins for the first resin.
  • the first resin and the second resin may be the same or different from each other.
  • the second resin is preferably selected from a resin that is compatible with the first resin.
  • the second resin may be a single kind of resin, or may be a combination of two or more kinds.
  • the functional layer may include a component other than the fiber and the second resin.
  • the component other than the fiber and the second resin include an inorganic filler, a releasing agent, a fire retardant and a colorant.
  • the melting temperature of the second resin is not particularly limited, and may be selected depending on the production method for the resin formed article.
  • the melting temperature of the second resin may be selected from the same range as the range of the melting temperature of the first resin. Since the second resin needs to be melted by contact with the first resin, the melting temperature of the second resin is selected so as to be equal to or lower than the melting temperature of the first resin.
  • the fiber included in the functional layer may be an inorganic fiber or an organic fiber, and may be selected depending on the purpose of the resin formed article.
  • Examples of the inorganic fiber include a carbon fiber, a glass fiber and a ceramic fiber.
  • Examples of the organic filer include an aramid fiber and a cellulose fiber.
  • the functional layer may include a single kind of fiber, or may include two or more kinds.
  • the fiber included in the functional layer may be in the form of a filament or a strand.
  • the proportion of the fiber in the functional layer is not particularly limited.
  • the proportion of the fiber in the total functional layer may be from 50% by mass to 85% by mass.
  • the state of the fiber in the functional layer is not particularly limited, as long as the first resin in a melted state can permeate though the functional layer.
  • Examples of the state of the fiber include a state in which the fiber is unidirectionally oriented; a state in which the fiber is oriented in orthogonally-crossed two directions; and a state in which the fiber is randomly disposed without being oriented in particular directions. It is possible to create a state in which the first resin in a melted state can permeate the functional layer by, for example, controlling a size of an area among the fiber (i.e., an area filled with the resin) in the functional layer.
  • the thickness of the functional layer is not particularly limited, as long as the first resin in a melted state can permeate.
  • the thickness of the functional layer may be 2,000 ⁇ m or less, or may be 1,000 ⁇ m or less, or may be 500 ⁇ m or less. From the viewpoint of achieving a sufficient effect of the functional layer, the thickness of the functional layer may be 10 ⁇ m or more.
  • the thickness of the functional layer may be constant or not constant. When the thickness of the functional layer is not constant, the thickness at least at a portion corresponding to a projection is selected from a thickness at which the first resin in a melted state can permeate.
  • the function that the functional layer imparts the resin formed article is not particularly limited, and examples thereof include reinforcement, electromagnetic wave-shielding, thermal insulation, antistatic properties and decoration.
  • the projection includes a first resin and a second resin. Namely, as described by referring to FIG. 1 , the projection includes a portion of the first resin that fills a concave portion corresponding to the projection, and a portion of the second resin that is melted by contact with the first resin and fills a concave portion corresponding to the projection.
  • a projection that is prepared in a separate process from the same resin as the first resin and the second resin, and is subsequently attached to the functional layer is not regarded as the projection according to the present disclosure.
  • Whether or not the projection includes a first resin and a second resin may be determined by a known process. For example, when the components of the main body, the functional layer and the projection of the resin formed article are analyzed, and a component that is in common with the main body (a first resin) and a component that is in common with the functional layer (a second resin) are included in the projection, respectively, it may be determined that the projection includes a first resin and a second resin.
  • the projection may include a component other than the first resin and the second resin.
  • the component other than the first resin and the second resin include an inorganic filler, a releasing agent, a fire retardant and a colorant.
  • the height of the projection (height of a portion rising from the functional layer) is not particularly limited, and may be selected depending on a desired function thereof or the like.
  • the height of the projection may be 0.5 mm or more, or may be 100 mm or less.
  • the thickness of the projection is not particularly limited, and may be selected depending on a desired function thereof or the like.
  • the thickness of the projection may be 0.5 mm or more, or may be 100 mm or less.
  • the shape of the projection is not particularly limited, and may be selected depending on a desired function thereof or the like.
  • the projection may have a plate-like shape, a hollow cylindrical shape, a cylindrical shape, or any other desired three-dimensional shape.
  • the projection may be a component generally referred to as a rib, a boss, a clip or the like, to be attached to the resin formed article.
  • the projection may have a shape satisfying a condition that a ratio of the thickness to the height (thickness/height) is 1.0 or less.
  • the method for producing a resin formed article according to the present disclosure is a method that includes: disposing a functional layer that includes a fiber and a second resin in a mold having a concave portion that corresponds to a projection of a resin formed article; and supplying a first resin in a melted state to the mold, the second resin having a melting temperature that is equal to or lower than a melting temperature of the first resin.
  • the second resin, included in the functional layer has a melting temperature that is equal to or lower than a melting temperature of the first resin. Therefore, a portion of the second resin in the functional layer (i.e., a second resin included in the basal region shown in FIG. 1 ) is melted by contact with the first resin in a melted state. As a result, it becomes possible for the first resin in a melted state to permeate through the fiber in the functional layer, and the first resin in a melted state flows toward a concave portion of the mold corresponding to a projection of the resin formed article. Along with the first resin, the second resin in a melted state flows toward a concave portion of the mold corresponding to a projection of the resin formed article.
  • the method may include pressurizing the first resin after the supplying the first resin to the mold.
  • the method for pressurizing the first resin is not particularly limited, and may be performed by a method of pressuring a space inside the mold by operating the mold (injection compression molding), for example.
  • the resin formed article produced by the method may satisfy the conditions of the resin formed article, as described above.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
  • Moulding By Coating Moulds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
US17/440,034 2019-03-27 2020-03-23 Resin formed article and method for producing resin formed article Pending US20220184897A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP2019-060079 2019-03-27
JP2019060079A JP7120113B2 (ja) 2019-03-27 2019-03-27 樹脂成形品及び樹脂成形品の製造方法
PCT/JP2020/012709 WO2020196402A1 (ja) 2019-03-27 2020-03-23 樹脂成形品及び樹脂成形品の製造方法

Publications (1)

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US20220184897A1 true US20220184897A1 (en) 2022-06-16

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US17/440,034 Pending US20220184897A1 (en) 2019-03-27 2020-03-23 Resin formed article and method for producing resin formed article

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CN113646152B (zh) 2023-06-23

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